Manufacture of actuators and control valve assemblies

ABSTRACT

An actuator for use in a control valve assembly that has a structure amenable to manufacture. The actuator may comprise a housing comprising a plurality of walls secured to one another with fasteners to form an interior cavity, a torque hub disposed in the interior cavity, the torque hub comprising a torque body and a torque arm that are releasably engaged with one another via fasteners, each of the torque body and the torque arm having interfacing geometry that defines surfaces that engage with opposing surfaces on the other; and a load generator coupled with the torque hub.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. ProvisionalApplication Ser. No. 62/331,997, filed on May 5, 2016, and entitled“CONTROL VALVE ASSEMBLY,” the content of which is incorporated byreference herein in its entirety.

BACKGROUND

Flow controls are important in many industries. Whether found on processlines, gas distribution networks, or like systems that carry flowingmaterial, flow devices like valve assemblies (or “control valves” or“control valve assemblies”) are vital to regulate material flow withinset parameters or, in case of problems, shut-off flow altogether. Inthis regard, control valve assemblies may include a valve that couplesin-line with the system to receive a flow of material. The valve mayhave components that move (e.g., translate, rotate, etc.) to restrict orpermit this flow. An actuator often accompanies the valve. The actuatorprovides force necessary to cause this movement. In some industrialapplications, torque required to operate the valve under high pressuremay well exceed 800,000 in/lbs.

SUMMARY

The subject matter of this disclosure relates to actuators as well ascontrol valve assemblies. Of particular interest herein are improvementsto simplify construction of actuators but still meet these rigorousperformance demands. In oil & gas industries, for example, theembodiments may operate valve assemblies on pipelines that flow naturalgas and oil at high pressures. As noted more below, the embodiments herepackage components to achieve such operability in a way that is bothsimple to construct and robust to adapt to a particular installation orapplication. These features reduce the need for secondary processing(e.g., machining, welding, etc.) and, more generally, reduce labor timeand costs to move the actuator from assembly to installation at acustomer site.

BREIF DESCRIPTION OF THE DRAWINGS

Reference is now made briefly to the accompanying drawings, in which:

FIG. 1 depicts a schematic diagram of an actuator;

FIG. 2 depicts a perspective view of an example of a torque hub for usein the actuator of FIG. 1;

FIG. 3 depicts a perspective view of the torque hub of FIG. 2;

FIG. 4 depicts the torque hub of FIG. 2 in exploded form;

FIG. 5 depicts an elevation view of the cross-section of the torque hubof FIG. 2;

FIG. 6 depicts an elevation view of the back of the torque hub of FIG.2;

FIG. 7 depicts a perspective view of an example of a torque hub for usein the actuator of FIG. 1;

FIG. 8 depicts the torque hub of FIG. 7 in exploded form;

FIG. 9 depicts a perspective view of an example of a control valveassembly that can included the actuator of FIG. 1;

FIG. 10 depicts an elevation view of the front of the control valveassembly of FIG. 9;

FIG. 11 depicts the control valve assembly of FIG. 10 with parts removedfor clarity;

FIG. 12 depicts a perspective view of the control valve assembly of FIG.11;

FIG. 13 depicts an elevation view of the back of the control valveassembly of FIG. 9;

FIG. 14 depicts an elevation view of the back of an example of thecontrol valve assembly of FIG. 9;

FIG. 15 depicts perspective view of the control valve assembly of FIG.14;

FIG. 16 depicts an elevation view of the front of the control valveassembly of FIG. 14;

FIG. 17 depicts the control valve assembly of FIG. 16 with parts removedfor clarity;

FIG. 18 depicts a perspective view of an example of a control valveassembly that can included the actuator of FIG. 1;

FIG. 19 depicts a perspective view of an example of a control valveassembly that can included the actuator of FIG. 1; and

FIG. 20 depicts an elevation view of the front of the control valveassembly of FIG. 19.

Where applicable, like reference characters designate identical orcorresponding components and units throughout the several views, whichare not to scale unless otherwise indicated. The embodiments disclosedherein may include elements that appear in one or more of the severalviews or in combinations of the several views. Moreover, methods areexemplary only and may be modified by, for example, reordering, adding,removing, and/or altering the individual stages.

DETAILED DESCRIPTION

The discussion that follows describes embodiments of actuators that arerugged, heavy duty devices. These embodiments have components made ofmaterials, like steel, that can withstand the high loads necessary forthe actuator to operate valve assemblies on high pressure oil andnatural gas pipelines. But rather than use large, pre-formed units,formed as weldments or castings, the embodiments leverage units that areof multi-piece designs. Additional components like pilot valves andcylinders can then integrate with these multi-piece units to finishassembly of the actuator. As discussed more below, this constructionavoids extensive re-work in order to reduce the costs in time and labornecessary to assemble, ship, and install the actuator in the field.Other embodiments are within the scope and subject matter of thisdisclosure.

FIG. 1 illustrates a schematic diagram of an exemplary embodiment of anactuator 10. This embodiment is shown as part of a control valveassembly 12, where the embodiment is useful to operate a process device14 to regulate flow of material 16 through a conduit 18. Examples of theconduit 18 may be part of a pipeline or a distribution system thatcarries hydrocarbon fluids (e.g., oil and natural gas). But the material16 may also comprise solids and solid/fluid mixes, as well. In thisregard, the process device 14 may embody a valve assembly having a valve20 with a closure member 22 and a seat 24. The actuator 10 may employ astructure 26 with a housing 28 to support the valve 20. The structure 26may also include a modular mounting system 30 to connect collateralcomponents, identified generally by the numeral 32. The collateralcomponent 32 may include, for example, pilot valves, manual controls,bleed valves, sensors, pressure instrumentation, and the like. Insidethe housing 28, the structure 26 includes a torque hub 34 that couples aload generator 36, like a pneumatic cylinder, with the closure member22. The torque hub 34 may also couple with a controller 38, often byconverting an incoming control signal to a proportional pneumatic signalfor use at the load generator 36. In turn, the torque hub 34 transfers aload L from the load generator 38 to locate the closure member 22 in aprescribed position relative to the seat 24. This position sets the flowof material through the valve 20.

Broadly, the structure 26 leverages construction to simplify manufactureand assembly of the control valve assembly 12. Such construction maytake advantage of multi-piece designs in place of castings and weldments(or “unitary structures”) that might find use for these types of devicesbecause of the rugged and robust nature necessary for their design. Thestructure 26 maintains these preferred characteristics, while at thesame time providing additional benefits that save on costs in labor andtime, both in manufacture and during installation in the field. Forexample, the housing 28 is configured to avoid much rework and secondaryor tertiary fabrication steps (e.g., machining) to finally assemble andship the control valve assembly 12. These configurations are effectiveto reduce tolerance issues that can lead to longer lead times. Thedesign also locates the torque hub 34 for ready access, for example, viaa removable door or panel on the housing 28. The modular mounting system30 is effective to allow for rapid integration of the collateralcomponents 34 in the control valve assembly 12. And the multi-piecedesign of the torque hub 30 allows a technician to accommodate for fitup issues of the control valve assembly 12 onsite at the installation orfacility. This feature accommodates for physical interferences not foundor determined in the original layout that defines the position ofequipment on “paper.” Engineers and designers may not recognize theseissues during initial solid modeling. But interferences can precludepositioning of the control valve assembly, for example, within proximityto certain other components. These issues may result in significantexpense and time lost because of the need to re-order new parts orre-work existing parts to properly install the valve assembly.

FIGS. 2 and 3 depict a perspective view of an example 100 of the torquehub 30 in assembled form. Referring first to FIG. 2, the exampleincludes one or more parts (e.g., a first part 102 and a second part104). The first part 102 (or “torque body 102) may comprise an elongatecylinder 106 having a central bore 108 with a longitudinal axis 110. Thesecond part 104 (or “torque arm 104”) may comprise one or more torqueplates (e.g., a first torque plate 112 and a second torque plate 114).The plates 112, 114 may form one or more connections (e.g., a firstconnection 116 and a second connection 118), both of which may beradially offset from the longitudinal axis 110. The connections 116, 118may engage with the actuator 10 (FIG. 1) or with collateral components34 (FIG. 1), as discussed more below. In one implementation, theconnections 116, 118 may be configured as joints, for example, as jointsformed by a pin 120 that extends between the plates 112, 114 (shown onlyat the first connection 116, but also possible at the second connection118); however this structure here should not work to limit the possibletypes of joints contemplated herein. A pin cover 121 might be includedover part of the pin 120 at the connections 116, 118 as well. Thiselement may releaseably engage with the plates 112, 114 to providestructure to engage with components (e.g., a shaft) that are useful toindicate position of the torque arm 104. An orifice or aperture may behelpful for this purpose.

The example also includes a fastening mechanism that is useful to couplethe cylinder 106 and the plates 112, 114. The fastening mechanism mayembody interfacing geometry 122 found on the cylinder 106 and plates112, 114. Fasteners 124 may also be useful to releaseably engage thecylinder 106 and the plates 112, 114. As best shown in FIG. 3, thecylinder 106 may include a connecting feature 128, shown as a keyway orslot that is formed in the central bore 108. When assembled with thevalve 20, the keyway 126 is configured to engage with a complimentaryboss (or like element) found on a shaft that connects to the closuremember 22 (FIG. 1). This configuration is useful to cause this shaft toco-rotate with cylinder 106 relative to the plates 112, 114, asindicated by the arrow denoted R about the longitudinal axis 110.Rotation R changes the angular position α of the keyway 126 relative tothe connections 118, 120, which in turn is useful to quickly orient thevalve 20 (FIG. 1) due to interferences with adjacent equipment or likeissues that would normally derail installation and require new orreworked parts.

FIG. 4 illustrates the example of FIG. 2 in exploded form. Starting withthe torque body 102, the cylinder 106 may have an outer surface 128 ofvarying dimensions (e.g., diameter). These dimensions may form anengagement region 130 that is configured to receive and engage theplates 112, 114. This configuration may include a central shoulderportion 132 that forms a pair of faces (e.g., a forward face 134 and arearward faces 136). Openings may populate the faces 134, 136,preferably in an array that circumscribes the longitudinal axis 110. Theopenings may comprise threaded holes 140 and counter-bored apertures142. However, the actual geometry of the openings 140, 142 may vary asnecessary to allow fasteners 124 to engage or pass through the materialof the cylinder 106 in a number sufficient to secure the cylinder 102and the plates 110, 112 under load L. Adjacent the central shoulderportion 132, the engagement region 130 may also include one or moreflatted portions (e.g., a first platted portion 144 and a second flattedportion 146). The flatted portions 144, 146 may include features, shownhere as flats 148, that populate the outer surface 128 of the cylinder106. As also shown, the dimensions of the outer surface 128 may formother areas (e.g., a first area 150, a second area 152, and a third area154) that may be useful to receive other components of the control valveassembly 12 (FIG. 1), as noted further below.

The plates 112, 114 may be configured to locate adjacent the faces 134,136 of the central shoulder portion 132. These configurations may have athin body 156, preferably comprising materials (e.g., metals,composites, etc.) that exhibit sufficient strength and stiffness (andother relevant physical properties) for the load L. The thin body 156may have a central aperture 158 with an axis 160. The central aperture158 may form an interior surface with flats 164 that circumscribe theaxis 160. At least some of the flats 164 may be configured with geometrycomplimentary to the geometry of the flats 148 on the flatted portions144, 146 of the cylinder 106. The complimentary geometry is useful todirect the load L to the cylinder 106 and, in turn, rotate the shaftthat couples with the closure member 22 (FIG. 1). In one implementation,the interior surface between the flats 164 may also include stressrelieving features. These features may take the form of chamfers 168 andfillets 170. But the form does not necessarily limit the stressrelieving feature, as other geometry may be helpful as well.

Looking at the exterior of the plates 112, 114, the thin body 156 mayhave a form factor of varying design. Geometry for the form factor mayaccommodate space and interferences inside the housing 28 (FIG. 1), butalso promote ease and simplicity of manufacture (e.g., using lasercutting or punch presses, for example). As shown here, the form factormay define a peripheral edge 172 having a first annular region 174disposed about the axis 160. The first annular region 174 may give wayto boss region 176, which extends longitudinally away from the axis 160.The boss region 176 may be square at its end, but other geometries(e.g., annular) may also result from fabrication. A second annularregion 178 may be formed at a location that is spaced radially away fromthe axis 160. The form factor may further form a shaped region 180 wherethe thin body 156 transitions between the annular regions 174, 178. Inthis transition, the peripheral edge 172 on opposite sides of the thinbody 156 may taper inwardly, or toward one another, from the largerdiameter of the first annular region 174 to the smaller diameter of thesecond annular region 178. In one implementation, the thin body 156 mayinclude a plurality of openings, shown here as a pin openings 180 in theregions 176, 178 to receive the pins 120 at the connections 116, 118.Fastener openings 182 may be dispersed across the face of the body 156,including circumscribing the central aperture 158. The fastener openings182 may receive fasteners 124, shown here in three sets (e.g., a firstset 184, a second set 186, and a third set 188).

FIG. 5 illustrates an elevation view of the cross-section of the exampleof FIG. 2 taken at line 4-4. The central bore 108 may include one ormore sections (e.g., a first section 190 and a second section 192). Thesections 190, 192 may be of different diameters to form a shoulder 194.In one implementation, the first section 190 is sized and configured toreceive at least a portion of a first shaft that couples with thecontroller 38 (FIG. 1). The second section 192 may, in turn, receive atleast a portion of a second shaft (or “valve shaft”) that couples withthe closure member 26 (FIG. 1).

FIG. 6 depicts an elevation view of the back of the example of FIG. 2.The keyway 126 may have a cross-section that is square or rectangular,but annular may suffice as well. The cross-section may be arranged sothat a plane P, which extends through the longitudinal axis 110, bisectsboth the keyway 126 and one of the flats 148 on the cylinder 106. Thisarrangement may be important to also align the keyway 126 (and, in turnthe valve shaft), with flats 172 on the plates 112, 114. In this regard,rotation R of the cylinder 106 will cause the annular position α tochange from a first annular position to a second annular position thatcorresponds to a different flat 172 on the plates 112, 114.

FIGS. 7 and 8 illustrate a perspective view of an example of the torquehub 30 in both assembled form (FIG. 7) and exploded form (FIG. 8). Inthis example, the first annular region 174 continues about the axis 160in lieu of the boss region 176 (FIG. 4) discussed previously. Thisconfiguration may be used when only one connection (e.g., the firstconnection 116) is required for operation of the control valve assembly12 (FIG. 1). As best shown in FIG. 7, one or more of the plates 112, 114may also include a curved recess 196 that extends along a portion of theperipheral edge 172. The curved recess 196 effectively removes or carvesaway material of the plates 112, 114. Further, the central shoulderportion 132 features a reduced diameter to allow fasteners 128 to bypassmaterial of the cylinder 106 to extend between plates 112, 114.

FIG. 9 depicts a perspective view of an example 200 of the control valveassembly 12. The housing 28 may form an enclosure 202 with one or morewalls 204, made and fastened to one another in a way sufficient tosupport several of the components of the apparatus 100 as well as theprocess device 14. The walls 204 may be thin, metal plates made of steelor of materials so as to exhibit physical properties (e.g., rigidity,strength, stiffness, etc.) necessary to support, at least in theaggregate, the corresponding components that affix, fasten, or aredisposed thereon. Fasteners including screws, bolts, and the like may beuseful to couple adjacent ones of the walls 204 together. Suchconstruction is useful to allow for rapid assembly, as opposed to, forexample, fully welded structures; however, it is contemplated that theuse of fasteners may combine with other fastening techniques (e.g.,welds) for this purpose. Parts of the enclosure 202 may also be formed acasting or cast part or machined from a single billet (block). In oneexample, one or more of the walls 204 may be clear or provide someoptical transparency to allow visual inspection of the inside of theenclosure 202.

The load generator 36 may be configured to reside on one of the walls204 (or the “top wall”) of the enclosure 202. This configuration mayinclude a pneumatic cylinder 206 and a spring cartridge 208, which iseffective to return or set the condition of the process device 14(FIG. 1) in the event of power or pneumatic outage or other problems atthe cylinder 206. The spring cartridge 208 may include a columnstructure 210 having a generally cylindrical column 212 with one or moreinterface plates (e.g., a first interface plate 214 and a secondinterface plate 216) disposed on either end. The cylindrical column 212may form a tube that is hollow and open at either end. The interfaceplates 214, 216 can also be thin, metal plates that are disposed betweenthe column 212 and the cylinder 206 (e.g., plate 214) and the column 212and the top wall of the enclosure 202 (e.g., the plate 216). The plates214, 216 can be configured to receive fasteners. This configuration isuseful to secure the cylinder 206 to the spring cartridge 208 as well asto secure the spring cartridge 208 in position on the top wall of theenclosure 202.

The controller 38 may be configured to couple with one of the walls 204(or the “front wall”) of the enclosure 202. This configuration mayinclude a positioner 218 that resides on the front wall of the enclosure202. The positioner 218 may couple with a control shaft 220 that extendthrough the front wall and couples with the torque hub (not shown). Thepositioner 218 may reside on a control mount 222 that itself couples tothe front wall. The control mount 222 may configured with individual,metal plates 224, but this design may also give way to variousconfigurations of parts or unitary monolithic design. The configurationspaces the positioner 218 off of the front wall of the enclosure 202,may dampen vibration and shock, as well as avoid other perturbationsthat could frustrate operation of the positioner 218.

The controller 38 may include a position indicator 226 that is useful toindicate the state or condition of the process device 14 to an observer.The position indicator 226 may form a gauge 228. In one example,indications on the gauge 228 correspond with the position (or movement)of the closure member 26 (FIG. 1). These indications may be part of amechanical indicator with one or more piece parts that mount to thefront wall or, even, that integrate as machined features in the frontwall of the enclosure 202. Suitable machine features may include anarcuate slot 230 that exposes the interior of the enclosure 202.Demarcations 232 such as lines may also reside proximate the slot 230 beuseful for this purpose. An indicator shaft 234 may extend from thetorque hub (e.g., from the pin cover 121, not shown) into or proximatethe slot 230. These piece parts operate as a mechanical indicator, forexample, where the location of the indicator shaft 134 may correspond tothe position of the first connection 116 (FIG. 1). However, thisdisclosure also contemplates use of display technology (e.g., screens,displays, etc.) that could provide some type of visual interface for theobserver to realize the movement or position of the closure member 26(FIG. 1).

FIG. 10 depicts an elevation view of the example 200 of FIG. 9. Themodular mounting system 30 is configured for rapid assembly ofcomponents without resort to significant rework or reprocessing ofparts. This configuration may include mounting members 236 for thispurpose. Examples of the mounting members 236 may be thin, elongateplates with one or more apertures 238 in the form of slots and holes,but geometry can vary to accommodate any design. The apertures 238 maybe dispersed in one or more of the longitudinal and axial directions oneach of the plates. In one implementation, the plates can attach to theinterface plates 214, 216. The modular mounting system 30 may alsoinclude one or more brackets 240. In use, the brackets 240 may couplewith the plates 236 using fasteners (e.g., screws, bolts, etc.) pins,bosses, and like elements. The plates 236 and brackets 240 can support,for example, collateral components like a pilot valve 242, manualcontrol 244, bleed valve 246, and canister 248. At least one benefit ofthe configuration of these pieces, however, is that they allow forvariations in the position of these components in, for example, avertical direction 250 based on which of the apertures 238 the devicesecures to on the plate 236.

FIGS. 11 and 12 depict the example of FIG. 10 with parts removed tofacilitate the discussion. Starting with FIG. 11, which shows anelevation view, the walls 204 create an interior cavity 252 that ishollow (or at least partially hollow). The interior cavity 252 can besized for certain components to support the torque hub 100. Thecomponents may include a bearing bracket 254 that affixes to the walls204 of the enclosure 202 via, in one example, one or more housingbrackets 256. A connecting rod 258 may couple at the first connection116. The connecting rod 258 may extend through the spring cartridge 208to couple with the cylinder 206. As best shown in the perspective viewof FIG. 11, the shafts 220, 234 can couple with the torque hub 100. Thecontrol shaft 220 may couple with the torque body 102. The indicatorshaft 234 may couple at the first connection 116. In operation, rotationof the torque hub 100 will cause corresponding movement in the shafts220, 234, which in turn communicates this movement to the respectivecontroller. For the indicator shaft 234, the offset of the firstconnection 116 will swing the shaft 234 in an arc that matches thearcuate slot 230 for the gauge 228 (FIG. 9).

FIG. 13 depicts an elevation view from the back of the example 200 ofFIG. 10. An aperture 260 in one of the walls 204 (the “back wall”)exposes the cylinder 106 of the torque hub 100. This feature providesaccess to the keyway 126. When assembled, the valve shaft may extendthrough the aperture 260 to engage with the cylinder 106, ofteninserting into the bore 108 to engage its corresponding boss featurewith the keyway 126.

FIG. 14 depicts an elevation view of the back the example 200 of thecontrol valve assembly 12, shown here with some additional componentsthat outfit the device to satisfy certain functional specifications. Theexample 200 includes one more valve brackets 262 to mount the valve 20to one of the walls 204 (the “back wall”) of the enclosure 202. Theexample may also include bracketry 264 that is configured to extend fromthe column 212 to the valve 20. The bracketry 264 may additionallysupport the weight of the valve 20, thus reducing any cantilever loadingthat may occur on the back wall of the enclosure 202.

FIGS. 15 and 16 depict the example 200 of FIG. 14 in perspective (FIG.15) and front, elevation (FIG. 16). The gauge 228 may form a stand-aloneunit 266 in lieu of the integrated design on the enclosure 202 discussedabove. The stand-alone unit 260 may reside on a secondary column 268found next to the spring cartridge 208 on the top wall of the enclosure202. The secondary column 268 may comprise a steel tube with cylindricalor square cross-section, although geometry preference may be given toother structures as well. The example 200 may also include a pair ofinterface plates (e.g., a third interface plate 270 and a fourthinterface plate 272), one each to secure the steel tube to the top wallof the enclosure 202 and to secure the stand-alone unit 266 in positionon the structure 200. As best shown in FIG. 15, the interface plate 272may have a portion that extends outwardly from the top wall of theenclosure 202. This portion may be configured (with an aperture or hole)to retain a filter 274 that filters particulates from incoming“instrument” fluid that is used to operate the cylinder 206.

FIG. 17 illustrates the front, elevation view of FIG. 16 with the frontwall of the enclosure 202 removed for clarity. The example 200 mayinclude a second connecting rod 276 that couples on one end with thetorque hub 100. The connecting rod 276 extends into the secondary column268 to the stand-alone unit 266 of the gauge 228. At the end, theconnecting rod 276 may comprise some intermediary component that caninterface with the gauge 228 to give proper indication of the positionof the valve 20.

FIG. 18 depicts a perspective view of the example 200 of the controlvalve assembly 12. Here, some components are arranged in slightlydifferent orientation. The positioner 218 may include an integrateddisplay in the form of one or more dial gauges 278 and a display 280.The integrated display may forgo the need for the position indicator(e.g., positioner indicator 226). In this regard, the example 200 mayleverage a cover plate 282, or like implement, to obscure any of theindication or demarcations that might be found on the front wall of theenclosure 202.

FIGS. 19 and 20 depict the example 200 of the control valve assembly 12.Other components may be included on the device to satisfy certainadditional functional specifications. The example 200 may include one ormore additional collateral devices (e.g., a first device 284 and asecond device 286). These collateral devices, like the ones notedbefore, can afford the control valve assembly 12 with certainfunctionality like pressure regulation, filtering, measurement, etc. Asbest shown in FIG. 20, the position indicator 226 includes an indicatingmechanism 288 that attaches to the first connecting rod 258. Theindicating mechanism 288 may include a shaft 290 that extends verticallyfrom the top wall of the enclosure 202. A moveable member 292 may couplewith the connecting rod 258. The moveable member 292 may extend to theshaft 290, possibly carrying a bearing 294 disposed therein thatcircumscribes the shaft 290. In use, movement of the connecting rod 258will displace the moveable member 292 to a position that correspondswith one of the demarcations 232 on the gauge 228.

In view of the foregoing discussion, the embodiments herein improveconstruction and use of actuators found as part of control valveassemblies. These improvements simplify the design to avoid unnecessaryparts and labor, while at the same time reducing the need to reworkexisting parts for fit-and-function. At least one other benefit of thesubject matter herein is to configure the device to adapt to changes inthe field. This feature may be of benefit to avoid interferences at thetime the device installs into the facility or location.

Further, this disclosure contemplates that replacement parts may be needand acquired in the aftermarket for the control valve assembly. In thisconnection, one or more of the replacement parts for the control system100 may be formed by existing parts. For example, parts of the couplingmechanism 112 or torque assembly 200 may lend itself to refurbishing andlike processes to prepare the existing parts into condition and/orspecification for use as the replacement part in the structure.Exemplary subtractive manufacturing processes may include buffing,bead-blasting, machining, and like practices that are useful to build-upand/or remove material from the part, as desired. Exemplary additivemanufacturing processes may include 3-D printing with polymers, lasermetal sintering, as well as after-developed technology.

The replacement parts may be assembled into control valve assembly as awholly-constructed assembly. In other implementations, the replacementparts may embody individual parts (e.g., the torque hub 10 or itspieces), as well as combinations and compilations thereof, possibly inthe form of one or more sub-assemblies.

Exemplary processes to manufacture these parts may leverage additivemanufacturing techniques, alone or in combination with one or more othertypes of subtractive manufacturing techniques. The process can includeconfiguring an additive manufacturing machine with executableinstructions that define a net shape. The net shape can embody thetorque hub 100 in whole or in part, including, for example,configurations of the body 106 or plates 112, 114 described hereinabove.The process may also include growing the net shape and, where necessaryperforming one or more post-growth processes on the net shape.

Implementations of the process 300 can render embodiments of the torquehub 100 or other components of the control valve assembly 200. Theseimplementations may result in, for example, control valve assemblycomprising a torque assembly with components (e.g., the body 106) madeby the process of configuring an additive manufacturing machine withexecutable instructions that define a net shape, growing the net shape,and performing one or more post-growth processes on the net shape. Suchimplementation that result in these parts are also contemplated whereinthe one or more post-growth processes comprises heat treating the netshape, and/or comprises de-burring the net shape, and/or comprisesmachining the net shape, and/or comprises apply a surface finish to oneor more surfaces of the net shape, and/or comprises removing material ofthe net shape using abrasives, and/or comprises inspecting the net shapeto accumulate dimensional data and comparing the dimensional data to adefault value.

As used herein, an element or function recited in the singular andproceeded with the word “a” or “an” should be understood as notexcluding plural said elements or functions, unless such exclusion isexplicitly recited. Furthermore, references to “one embodiment” of theclaimed invention should not be interpreted as excluding the existenceof additional embodiments that also incorporate the recited features.

This written description uses examples to disclose the embodiments,including the best mode, and also to enable any person skilled in theart to practice the embodiments, including making and using any devicesor systems and performing any incorporated methods. The patentable scopeof the embodiments is defined by the claims, and may include otherexamples that occur to those skilled in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal language of the claims.

Examples below include certain elements or clauses one or more of whichmay be combined with other elements and clauses describe embodimentscontemplated within the scope and spirit of this disclosure.

1. An actuator, comprising: a housing comprising a plurality of wallssecured to one another with fasteners to form an interior cavity; atorque hub disposed in the interior cavity, the torque hub comprising atorque body and a torque arm that are releasably engaged with oneanother via fasteners, each of the torque body and the torque arm havinginterfacing geometry that defines surfaces that engage with opposingsurfaces on the other; and a load generator coupled with the torque hub.2. The actuator of claim 1, wherein the surfaces form flats on an outersurface of the torque body.
 3. The actuator of claim 1, wherein thesurfaces form flats disposed on an inner surface of an aperture on thetorque arm.
 4. The actuator of claim 1, wherein the torque arm comprisesa plurality of plates spaced longitudinally apart from one another. 5.The actuator of claim 1, wherein the torque arm forms a clevis jointthat is spaced radially apart from the torque body and that couples withthe load generator.
 6. The actuator of claim 1, further comprising: aposition indicator that couples with the torque hub, the indicatormechanism generating a visual indicator that corresponds with an annularposition of the torque arm.
 7. The actuator of claim 1, wherein thetorque body has an engagement region forming a shoulder portion thatseparates the interfacing geometry into a pair of flatted portions thatdefine the surfaces on the torque body.
 8. The actuator of claim 1,wherein the torque body comprises a cylinder with a central bore forminga keyway at least at one end.
 9. The actuator of claim 1, wherein thekeyway aligns with a plane that bisects one of the surfaces of theinterfacing geometry on the torque body.
 10. The actuator of claim 1,wherein the torque hub includes a pair of pins, one each extendingthrough openings in the plates on radially opposite sides of the torquehub.
 11. An apparatus, comprising: a housing; a pneumatic actuatorcoupled to a first wall of the housing; a controller coupled to a secondwall of the housing that is different from the first wall, thecontroller coupled with the pneumatic actuator to deliver a pneumaticsignal; a cylinder disposed in the housing, the cylinder coupled on afirst end with the controller and exposed on a second end via an openingin a third wall of the housing that is different from the first wall andthe second wall, a pair of plates releasably engaged with the cylindervia fasteners, and a first pin coupled with the pneumatic actuator andextending through the pair of plates and spaced radially away from thecylinder.
 12. The apparatus of claim 11, wherein the cylinder and thepair of plates have interfacing geometry that defines surfaces thatengage with opposing surfaces on the other.
 13. The apparatus of claim11, further comprising: a shaft extending from the controller to thecylinder.
 14. The apparatus of claim 11, further comprising: a shaftextending from the joint to an arcuate slot in the second wall.
 15. Theapparatus of claim 11, further comprising: a position indicator coupledwith the first wall of the housing; and a second pin coupled with theposition indicator, the second pin extending through the pair of platesand spaced radially away from the cylinder and the first pin.
 16. Theapparatus of claim 11, further comprising: a spring cartridge interposedbetween the pneumatic actuator and the first wall of the housing.
 17. Amethod for actuating a valve, comprising: receiving a load from apneumatic actuator on a first joint formed by a pair of plates;directing the load to a cylinder via interfacing geometry that definessurfaces that engage with opposing surfaces on the pair of plates, thesurfaces found on an outer surface of the cylinder and on an innersurface of an aperture that penetrates both of the pair of plates andthat receives the cylinder therein; and using the load to rotate a shaftof a valve that couples with the cylinder.
 18. The method of claim 18,further comprising: indicating position of the cylinder using the firstjoint.
 19. The method of claim 18, further comprising: indicatingposition of the cylinder using a second joint formed by the pair ofplates.
 20. The method of claim 18, further comprising: engaging thecylinder and the shaft with a keyway.